Multi-Directional Steerable Catheter

ABSTRACT

A bi-directional steerable catheter adapted for delivery into a patient&#39;s vasculature. The pull wires which are used to tension the deflectable segment of the steerable catheter are wound in parallel around the axis of the steerable catheter on opposite sides of the steerable catheter.

FIELD OF THE INVENTIONS

The inventions described below relate to the field of steerable guide catheters, sheaths and introducers.

BACKGROUND OF THE INVENTIONS

Steerable catheters, including steerable guide catheters, guide sheaths and introducer sheaths, are used to gain access to the desired target location within the vasculature of a patient and provide a safe, smooth conduit to guide and support another device, such as an interventional catheter, to a target location in the vasculature of a patient. The interventional catheter is typically a delivery device that carries an implant for deposit in the vasculature, or an active device that carries out the diagnosis, therapy or intervention. Guide catheters, guide sheaths and introducer sheaths can also be used to pass fluids for visualization, diagnosis or treatment. Provision of steering mechanisms in these catheters facilitates their navigation through the vasculature of a patient, to gain access a target site.

SUMMARY

The steerable catheters described below provide for easy, atraumatic access to areas of the vasculature that are otherwise difficult to access, while minimizing the propensity of pull-wire operated steerable catheters to whip, or rapidly snap from one configuration to another, as the pull wire is tensioned to steer the device. The steerable catheters described below are constructed with components that are selected to provide optimal stability to prevent whipping. The steerable catheter includes two or more pull wires which are wound along a portion of the steerable catheter, around the long axis of the steerable catheter, in parallel and circumferentially on opposite sides of the steerable catheter, to balance the off-axis forces applied by the pull wires, and thus prevent whipping and avoiding changes in curve geometry achieved by manipulation of the pull wires when the steerable catheter is deployed within the vasculature such that the wound portion of the steerable catheter runs through a bend in the vasculature. The curve in the vasculature may be any tortuosity such as the aortic arch, the iliac bifurcation, the atrial septum, the brachial artery inlet from the aorta, etc. The deflection segment curve geometry remains more stable when the steerable catheter is rotated around its long axis. The minimization of whipping is very effective, and the deflection segment curve geometry remains more stable, where the steerable catheter components are arranged along the length of the steerable catheter such that the wound segments coincide with the expected bend in the vasculature in the vasculature in which it is deployed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the steerable catheter.

FIG. 2 is a schematic view of the steerable catheter with wound pull wires.

FIG. 3 is a perspective view of the steerable catheter and the wound pull wires.

FIG. 4 is a cross section of the steerable catheter of FIG. 1.

FIGS. 5 and 6 illustrate the control handle of the deflectable steerable catheter of FIG. 1.

FIG. 7, which illustrate the steerable catheter 1 disposed within the vasculature of a patient

DETAILED DESCRIPTION OF THE INVENTIONS

FIG. 1 illustrates the deflectable steerable catheter. The steerable catheter 1 comprises a steerable catheter tube (2 with a catheter handle 3 mounted on the proximal end 4 of the steerable catheter tube and a deflectable segment at the distal end 5, and a lumen extending through the tube. The steerable catheter tube includes the first, deflectable segment 2 d which is operated by a pull wire, a second, wound segment 2 w (extending proximally from the first segment) in which the pull wires are wound around the catheter (shown in FIGS. 2 through 4), and, optionally, a third, proximal segment 2 p (extending proximally from the second segment), in which the pull wire runs straight on opposite sides of the steerable catheter tube. The catheter handle includes a steering lever 6, which can be turned by a user to manipulate an internal steering mechanism (show in FIGS. 5 and 6) and the pull wires, and thus deflect the deflectable segment in to an arcuate configuration, and a brake 7 which can be manipulated to lock the steering mechanism in any selected position and thus hold the deflectable segment in an arcuate configuration selected by the user of the device, and corresponding to the rotational position of the steering lever. As shown in phantom, the deflectable segment 2 d is operable, through manipulation of the steering lever, to bend through a significant arc, away from the longitudinal axis 8, in two directions in the same plane (where two pull wires are provided), so that the tip can be deflected through an arc intersected by the longitudinal axis, without the need to rotate the steerable catheter about the longitudinal axis. This behavior is referred to bi-directional steering.

FIGS. 2 and 3 illustrate the steerable catheter and wound pull wires embedded within the catheter wall and arranged to provide steering without whipping. The major components of steerable catheter tube 2 include the catheter wall 9 comprising an outer tube or jacket 10 and an inner tube 11, and two pull wires 12 and 13 disposed between the outer tube and the inner tube. In the wound segment of the steerable catheter (2 w in FIG. 1), the pull wires are wound about the longitudinal axis of the tube, and each pull wire is wound in the same direction as the other pull wire in wound wire segments 12 w and 13 w, preferably substantially in parallel, to create a segment of the steerable catheter in which the pull wires are wound on circumferentially opposite sides of the steerable catheter at each point along the length of the wound segment 2 w (that is, in any radial cross section, the wound wires will be on opposite sides of the steerable catheter, though along the s of the wound segment the pull wire wrap around the steerable catheter). Each pull wire has a straight distally extending segment 12 d and 13 d, extending from the wound segment, toward the distal end of the steerable catheter (corresponding to the deflectable segment 2 d in FIG. 1), and a straight proximally extending segment 12 p and 13 p extending proximally from the wound segment toward the proximal end of the steerable catheter (corresponding to the proximal segment 2 p in FIG. 1), where they are fixed to the control mechanism shown in FIG. 4. The straight distally extending segments 12 d and 13 d correspond to the deflectable segment 2 d of FIG. 1. The pull wires may be disposed within separate side lumens in the wall of the inner tube or outer tube or they may be disposed within separate smaller tubes secured over the inner tube.

In the wound segment of the steerable catheter (2 w in FIG. 1), the pull wires may be counter-wound, rather than parallel, with each pull wire wound in a direction opposite the other pull wire in wound wire segments 12 w and 13 w, to create a segment of the steerable catheter in which the pull wires are counter-wound. The counter-wound segments of the pull wires may be wound with one pull wire within the other, or they may be braided.

FIG. 4 is cross section of the steerable catheter, showing additional layers of the steerable catheter. As shown in FIG. 4, the deflectable segment 2 d of the steerable catheter tube 2 consists of the inner tube 11, and straight distally extending segments 12 d and 13 d of the pull wires (disposed on opposite side of the steerable catheter, about 180° apart, both within 0.001″ thick PTFE pull wire liners), the deflectable segment also includes a braid 14 d (1 over 1 under, 20-30 picks per inch), over the inner tube 11 and the pull wires, all within the outer tube 10. Where the inner tube comprises PTFE, no liner may be necessary, but in alternative embodiments in which the inner tube comprises another polymer, the deflectable segment may consist of, in addition to the layers just listed, a PTFE liner 15, disposed within the inner tube. The braid 14 d may be embedded in a low durometer polymer, in which case the deflectable segment may consist of, in addition to the layers listed above, the braid embedded in a low durometer polymer.

A segment 2 w proximal to the deflectable segment, in which the two pull wires are wound about the axis of the steerable catheter, consists of the inner tube 11, then the wound segments of the pull wires (12 w and 13 w ), a second braid segment 14 w (1 over 2 under, at 70-80 picks per inch), within the outer tube 10. (The second braid segment 14 w may be an continuous extension of the braid 14 d in the deflectable segment, or it may be a discrete additional component.) Again, where the inner tube comprises PTFE, no liner may be necessary, but in alternative embodiments in which the inner tube comprises another polymer, the wound segment 2 w may consist of, in addition to the layers just listed, the PTFE liner 15, disposed within the inner tube. The braid 14 w may be embedded in a high durometer polymer, in which case the deflectable segment may consist of, in addition to the layers listed above, the braid embedded in a high durometer polymer. An additional braid 16 may be embedded in the outer tube (this braid extends proximally to the pull wire exit at the proximal end of the tube, and is preferably wound at 80 picks per inch for some applications, and 20 picks per inch for other applications). Where, in alternative embodiments, the additional braid 16 is used, the wound segment 2 w may consist of, in addition to the layers listed above (the inner tube 11, the pull wires 12 and 13, the braid 14 w and the outer tube 10, or the liner 15, the inner tube 11, the pull wires 12 and 13, the braid 14 w and the outer tube 10), the additional braid 16.

A third, proximal-most segment 2 p, in which the two pull wires run straight along the length of the catheter, from the wound segments of the pull wire to connections in the handle, consists of, or comprises, the inner tube 11, the second braid 14 w (the same braid as in the wound segment)(1 over 2 under, at 70-80 picks per inch), then the straight segments of the pull wires (12 p and 13 p ) within the outer tube 10. Again, where the inner tube comprises PTFE, no liner may be necessary, but in alternative embodiments in which the inner tube comprises another polymer, the proximal segment may consist of, in addition to the layers just listed, the PTFE liner 15, disposed within the inner tube. The braid 14 w may be embedded in a high durometer polymer, in which case the deflectable segment may consist of, in addition to the layers listed above, the braid embedded in a high durometer polymer. As in the wound segment, the additional braid 16 may be embedded in the outer tube in the third, proximal-most segment 2 p. Where, in alternative embodiments, the additional braid 16 is used, the wound segment 2 w may consist of, in addition to the layers listed above (the inner tube 11, the pull wires 12 and 13, the braid 14 w and the outer tube 10, or the liner 15, the inner tube 11, the pull wires 12 and 13, the braid 14 w and the outer tube 10), the additional braid 16.

A soft tip 17 covers the distal tip of the device. The hardness of the outer tube can be very soft at the distal tip at 35D, and transition to progressively harder formulation of 55D proximate the distal end of the wound segment, and then transition further to a harder formulation of about 72D proximate the proximal end of the wound segment, and remain at about 72D or harder for the remaining proximal portion of the steerable catheter.

While the steerable catheter is illustrated with two pull wires, the benefits of the wound pull wires can be achieved with a plurality of pull wires obtain steerability across several planes. For example, the steerable catheter may comprise three or four pull wires, dispersed (preferably evenly distributed) about the circumference of the steerable catheter and wound substantially in parallel in the wound segment, to provide steering along arcs lying in additional planes.

FIGS. 5 and 6 illustrates the catheter handle of the deflectable steerable catheter of FIG. 1, with a braking system that can be used with the pull wire system of FIGS. 1 through 4. The catheter handle 3 is fixed to the steerable catheter tube 2. The inner tube 11 of the catheter extends through the catheter handle to the feeder tube 21, so that working catheters can be fed into the steerable catheter. The proximal tips of the pull wires 12 p and 13 p are fixed to the steering lever 6 at joints 22 and 23, through any convenient means. In order to provide a mechanism to hold the lever and pull wires in a chosen position, to maintain an arcuate configuration of the deflectable segment, the lever is also rotationally fixed to the round disc 24, which turns in tandem with the pull wire joints 22 and 23, and a brake 25 comprising a cam plate 26 and lever 27 is disposed on the handle such that the rotation of the brake lever rotates cam plate into interfering contact with the disc and prevents the disc from rotating. The brake lever and cam plate are held in position by friction between the lever and cam and the fittings use to connect them to the housing. This is shown in FIG. 6, in which the steering lever has been rotated about its fulcrum 28 (with each pull wire fixed to the lever on opposite sides of the fulcrum) to pull the pull wire 12 proximally, while relieving tension and allowing pull wire 13 to translate distally, and the braking lever has been rotated to jam the cam plate into interfering contact with the disc to hold it in place. Though this braking system is particularly suited for use with the pull wire system of FIGS. 1 through 5, the advantages of the braking system can be obtained with other pull wire systems, and the advantages of the pull wire system can be used with other braking systems. A hemostatic valve 29 is provided at the proximal end of the feeder tube 21.

The inner and outer tube may comprise PEBAX® 7033 SA01 MED WITH FOSTER Propell, or ProPell™ thermoplastic polyurethane (TPU) for the inner tube. The liner, when used, may comprise PTFE. The braids may comprise stainless steel braids of between 25 and 100 picks per inch, or the more preferable pick counts expressed above. The braids are preferably made of flat wire about 0.007″ wide by 0.001″ thick in a 5.5 French internal diameter configuration and may be larger in larger configurations and smaller in smaller configurations. The braid of the deflectable segment is preferably embedded in a low durometer polymer such as Pebax at 30D to 35D. The braid of the wound segment is preferably embedded in a high durometer polymer such as Pebax at about 72D. The braid of the deflectable segment can be annealed to increase its flexibility, by, for example, heating the stainless steel braid at high temperature (about 1100° F., or 600° C.) for about two minutes. The pull wires are preferably stainless steel round pull wires with a diameter of about 0.006″ or flat pull wires about 0.010″ wide by 0.003″ thick covered in a PTFE liner with a wall thickness of about 0.001″. The pull wires may also comprise a stainless steel braid, or a para-aramid synthetic fiber (Kevlar®) tension element. The resultant overall wall thickness for a steerable catheter with a 5.5F internal diameter, in the deflectable segment and wound segment, may be about 0.3 to 0.4 mm, preferably about 0.367 mm (about 1.1F). The resultant overall wall thickness for a steerable catheter with an 11F internal diameter, in the deflectable segment and wound segment, may be about 0.6 to 0.8 mm, preferably about 0.734 mm (about 2.2F). In such larger diameter cross sections and walls, larger cross sectional area for pull wires and for braid wire material may be used. (Likewise in smaller diameter devices than the 5.5 French internal diameter configuration disclosed these cross sectional areas could be smaller.) These parameters may be varied to adjust the torque transmission, pushability and trackability of steerable catheters for particular applications. Suggested overall dimensions of the steerable catheters for particular applications are as follows:

Clinical Applications/ Proximal Wound Defl. Target Site Segment segment Segment ID Femoral vein access across 55 cm 10 cm 5 cm 8.5F the atrial septum access of the left atrium for AF ablation Femoral vein access across 55 cm 10 cm 5 cm 8.5F, the atrial septum to the 10.5F left atrium for mitral 12.5F valve repair 14.5F Femoral artery access 80 cm 15 cm 5 cm 3.5F across the aortic arch for 4.5F left ventricular 5.5F procedures from femoral access for transendocardial biotherapeutic intervention and coronary artery intervention and peri-valvular leak, Femoral artery access 80 cm 15 cm 5 cm 12F across the aortic arch for 14F left ventricular 16F procedures from femoral 18F access 20F for aortic valve implantation Radial artery access to 50 cm 15 cm 40 cm  4.5F the peripheral vasculature 5.5F of the aorto ostial region for peripheral interventions Radial artery access to 50 cm 20 cm 70 cm  4.5F the peripheral vasculature 5.5F superior femoral artery for peripheral interventions Radial artery access to 50 cm 20 cm 10 cm  3.5F the Aortic arch cardiac 4.5F interventions such as 5.5F peri-valvular leak, transendocardial delivery Carotid access 80 cm 15 cm 5 cm 3.5F 4.5F 5.5F

Given these dimensions and the typical size and anatomy of patients, the steerable catheter components are arranged along the length of the steerable catheter such that the wound segments coincide with the expected bend in the vasculature on along predetermined access routes. Generally, the steerable catheter is constructions with dimensions for the deflectable segment and the wound segment such that, when inserted through a predetermined access point, with the deflectable segment disposed at a target site, the wound segment is disposed within curved portion of the vasculature. Depending on the target site, the curved portion may be the aortic arch, the transition from the inferior vena cava to the atrial septum, the iliac bifurcation (for access from on iliac artery to its contralateral iliac artery), the brachiocephalic trunk or the aorta of the patient artery or the aortic arch (for trans-radial access to the renal arteries), or other tortuosity that may be encountered between the entry point and the target site. For example, for access to the left atrium of a patient, from the femoral vein, the curve of the right atrium is expected be located about 55 to 65 cm from the entry point into the vasculature (a cut-down in the thigh of the patient). Thus the steerable catheter for access to the atrial septum from the femoral vein is constructed such that, when the inserted in the vasculature, with the deflectable segment disposed within the right atrium, proximate the atrial septum of the patient (where deflection facilitates crossing into the left atrium of the patient), the wound segment is disposed, in curved configuration, across the right atrium. This can be accomplished, as indicated in the table above, with a steerable catheter having a 5 cm deflectable segment at the distal and of the steerable catheter, followed by a 10 cm wound segment, followed by a proximal segment of at least 55 cm (the proximal segment lengths described in the table may be considered minimum lengths). This relationship between the steerable catheter structure and the vasculature of a patient is shown in FIG. 7, which illustrate the steerable catheter 1 used access portions of the heart 30, with the steerable catheter disposed within the vasculature of a patient, in the pathway leading from the femoral vein, up the inferior vena cava 31, through the right atrium 32, through the atrial septum 33 an into the left atrium 34, such that the deflectable segment 2 d is disposed proximate the target site of the left atrium and the wound segment 2 w is disposed, in a curved configuration, along around the curve leading from the vena cava to the atrial septum. The proximal segment 2 p extends downs the inferior vena cava to the entry point in the femoral vein. In use, the steerable catheter is inserted into the vasculature, navigated through the vasculature until the deflectable segment of the steerable catheter is disposed proximate the target site, and, with a properly sized steerable catheter, the wound segment is disposed across a curve in the vasculature. Once properly placed, the deflectable segment can be deflected by operation of one or more pull wires (tensioning or releasing tension), through manipulation of the steering mechanism on the proximal handle. During manipulations of the pull wires and deflection of the deflectable segment, the wound segment, by virtue of the wound nature of the pull wires, will experienced circumferentially balances forces and be much less likely to change its configuration or experience whipping common in other steerable catheters. The method can be used to access many target sites, including each of the target sites listed in the table, through corresponding insertion sites.

Though the steerable catheter has been described in relation to guide catheters, guide sheaths and introducer sheaths, the inventive aspects of the steering mechanisms can be adapted to any catheter. Thus, while the preferred embodiments of the devices and methods have been described in reference to the environment in which they were developed, they are merely illustrative of the principles of the inventions. The elements of the various embodiments may be incorporated into each of the other species to obtain the benefits of those elements in combination with such other species, and the various beneficial features may be employed in embodiments alone or in combination with each other. Other embodiments and configurations may be devised without departing from the spirit of the inventions and the scope of the appended claims. 

1. A steerable catheter comprising: a tube (2) having a proximal end (4), a distal end (5), and a lumen extending therebetween, said tube (2) having a first segment (2 d ) proximate said distal end and second segment (2 w ) that extends proximally from said first segment (2 d ) toward said proximal end, a first pull wire (12) and a second pull wire (13) embedded within a wall of the tube, and extending from the distal end (5) to the proximal end (4) of the tube (2), said first and second pull wires comprising first and second wound segments (12 w, 13 w) which are wound about a longitudinal axis of the tube, with the first pull wire (12) wound in a first direction and the second pull wire (13) wound in the first direction, substantially in parallel with the first pull wire with the first wound segment (12 w) and the second wound segment (13 w) dispersed circumferentially about the longitudinal axis of the tube (2).
 2. The steerable catheter of claim 1, wherein: said first and second pull wires comprise first and second straight distally extending segments (12 d, 13 d) extending distally from the respective wound segments (12 w, 13 w); and the first and second straight distally extending segments (12 d, 13 d) are disposed within the first segment (2 d) of the tube; and the first and second wound segments (12 w, 13 w) are disposed in the second segment of the tube.
 3. The steerable catheter of claim 2, wherein: in the first segment (2 d) of the tube, the tube wall consists of an inner tube (11), the pull wires (12 d, 13 d) disposed about the inner tube (11), a braid (14) embedded in a low durometer polymer disposed about the inner tube (11) and pull wires (12 d, 13 d), and the outer tube (10) disposed about the braid (14).
 4. The steerable catheter of claim 2, wherein: in the second segment (2 w) of the tube, the tube wall consists of an inner tube (11), the wound segments (12 w, 13 w) of the pull wires disposed about the inner tube (11), the braid (14) embedded in a low durometer polymer disposed about the inner tube and pull wires, an additional braid 16 disposed about the braid (14), and the outer tube 10 disposed about the additional braid
 16. 5. The steerable catheter of claim 2, wherein: in the first segment of the tube, the tube wall consists of a liner (15), an inner tube (11) disposed about the liner, the pull wires (12 d, 13 d) disposed about the inner tube (11), a braid (14) embedded in a low durometer polymer disposed about the inner tube and pull wires, and the outer tube 10 disposed about the braid (14).
 6. The steerable catheter of claim 2, wherein: in the second segment of the tube, the tube wall consists of a liner (15), an inner tube (11) disposed about the liner (15), the wound segments (12 w, 13 w) of the pull wires disposed about the inner tube (11), a braid (14) embedded in a low durometer polymer disposed about the inner tube and pull wires, and the outer tube 10 disposed about the braid.
 7. The steerable catheter of claim 1, wherein: first and second wound segments (12 w, 13 w) each comprise three turns about the longitudinal axis of the tube.
 8. The steerable catheter of claim 2, further comprising: a third segment (2 p ) of the tube (2) extending proximally from the second segment (2 w ) to the proximal end of the tube; and the first pull wire (12) and a second pull wire (13) each comprise a straight proximally extending segment (12 p and 13 p ) extending proximally from the wound segment toward the proximal end (4) of the tube (2); and said straight proximally extending segments (12 p and 13 p ) of the pull wires are disposed within the third segment (2 p ) of the tube.
 9. The steerable catheter of claim 1, further comprising: handle (3) fixed to the steerable catheter tube (2), said handle comprising: a steering lever (6) rotatably secured to the handle at a fulcrum (28), with the first and second pull wires (12, 13) fixed to the steering lever (6)on opposite sides of the fulcrum (28); and a disc (24) rotationally fixed to the steering lever (6); a brake (7) disposed on the handle such that the rotation of the brake prevents rotation of the disc (24), thereby holding the deflectable segment (2 d ) in a configuration corresponding to the rotational position of the steering lever (6).
 10. The steerable catheter of claim 9, wherein the brake comprises: a brake lever (27) and a cam plate (26), disposed on the housing such that the rotation of the brake lever (27) rotates the cam plate (26) into interfering contact with the disc (24) and prevents the disc (24) from rotating.
 11. A method of accessing a target site in the vasculature of a patient, said method comprising the steps of: providing a steerable catheter comprising: a tube (2) having a proximal end (4), a distal end (5), and a lumen extending therebetween, said tube (2) having a first segment (2 d ) proximate said distal end and second segment (2 w ) that extends proximally from said first segment (2 d ) toward said proximal end, one or more pull wires embedded within a wall of the tube, and extending from the distal end (5) to the proximal end (4) of the tube (2), said pull wires comprising wound segments (12 w, 13 w) which are wound about a longitudinal axis of the tube; inserting the steerable catheter into the vasculature of the patient, and navigating the steerable catheter through the vasculature of the patient until the deflectable segment is disposed proximate the target site and the wound segment is disposed across a curve in the vasculature; and operating one or both of the pull wires to deflect the deflectable segment.
 12. The method of claim 11, wherein the steerable catheter comprises at least two pull wires, and the wound segments are dispersed about the circumference of the steerable catheter.
 13. The method of claim 11, wherein the target site is a left atrium and the curve is the curve is a transition from an inferior vena cava to an atrial septum of the patient.
 14. The method of claim 11, wherein the target site is an iliac artery of a patient and the curve is an iliac bifurcation of the patient.
 15. The method of claim 21, wherein the target site is a left ventricle of a patient and the curve is an aortic arch of the patient.
 16. The method of claim 11, wherein the target site is a coronary artery of a patient and the curve is an aortic arch of the patient.
 17. The method of claim 11, wherein the target site is an aortic valve of a patient and the curve is an aortic arch of the patient.
 18. The method of claim 11, wherein the target site is a peripheral blood vessel of a patient and the curve is a tortuosity between the target site and an entry point into the vasculature of the patient.
 19. The method of claim 11, wherein the target site is a carotid artery of a patient and the curve is bifurcation of the brachiocephalic trunk or the aorta of the patient.
 20. The steerable catheter of claim 8, further comprising: handle (3) fixed to the steerable catheter tube (2), said handle comprising: a steering lever (6) rotatably secured to the handle at a fulcrum (28), with the first and second pull wires (12, 13) fixed to the steering lever (6)on opposite sides of the fulcrum (28); and a disc (24) rotationally fixed to the steering lever (6); a brake (7) disposed on the handle such that the rotation of the brake prevents rotation of the disc (24), thereby holding the deflectable segment (2 d ) in a configuration corresponding to the rotational position of the steering lever (6). 